I think there are online websites that can do it. Never done it before so don't know the trustworthiness or if your dealing with sensitive data
If you absolutely can't, you can export one page at a time from word to pdf using the Options button after clicking Create PDF / XPS.
But I would first turn on Show/Hide both in the template and in the merged documents to see if there's an extra page break. And as far as the font, you can right click and toggle field codes (there's also a keyboard shortcut) and add or take out MERGEFORMAT. I've had the font problem before and some fussing and googling usually fixed it.